Means for controlling current flow in electric circuits



M. F. SPEARS May 8, 1956 MEANS FOR CONTROLLING CURRENT FLOW IN ELECTRIC CIRCUITS Filed June 16, 1953 LOA D r. I l l I I l I I I l f Izwezzor: 210343032/ United States Patent O MEANS FOR CONTROLLING CURRENT FLOWJ ELECTRIC CIRCUITS Morton F. Spears, Westwood, Mass. Application June 16, 1953, Serial No. 361,921

14 Claims. (Cl. 200-113) This invention relates to a means for controlling the e such units are herein illustrated), from another point of view the invention provides a material of construction from which such or similar units may be formed. Such a material might be considered a composition of matter embodying two components which have differentiated properties of electrical conductivity and of thermal ex- Y pansion. These components are not mechanically connected as are the elements of a machine although they form a mechanical mixture. As in any such mixture the properties of the mixture are determined not only by the physical properties of the components (conductivity and expansibility) but also by the physical form of the components and their relative physical positions of juxtaposition in the composition. The object of the invention is to provide such a material which may be inexpensively produced in forms having different electrical values to suit various uses and which may be easily and simply utilized in compact units for different applications. A coordinate object is to provide such a material which will function accurately and repeatedly under the conditions of use. It will have no moving parts as those words are usually understood and may be utilized in remote or otherwise inaccessible locations since .direct access thereto will not be required to replace or to reset it after it has once functioned. The invention will be well understood by reference to the following description taken in connection withl the somewhat schematic representations of several embodiments thereof shown by way of example in the accompanying drawings, wherein: Y Fig. 1 is awiring diagram including a somewhat conventionalized longitudinal cross sectional view on an enlarged scale of a device exemplifying the subject matter of the invention and functioning in the manner of a circuit breaker;

' Fig. 2 isa section on the line 2 2 of Fig. l; i Fig. 3` is a View similar to Fig. l showing the operation of the circuit breaker under abnormal conditions; Fig. 4 is a cross sectional View of a modified form of the device applicable for the same purposes as in Fig. l; Fig. 5 is a section on line 5 5 of Fig. 4; v Fig.` 6 isa longitudinal crossv sectional view of a further modification; and i Fig'. 7 isa conventionalized longitudinal cross sectional view of another modification on a still larger scale, one more particularly adapted for use with heavy currents. In this figure the insulation is omitted at the right to disclose small masses wholly at the rear of the sectioning plane.

i Referring to Figs. 1, 2 and 3, there is'there shown in connection with the diagrammatic disclosure of elements ICC of an electric circuit a controlling device illustrative of the invention shown with some realism, but nevertheless schematically. The device shown includes av row ofthree small contacting balls 10 of conductive material, say of invar alloy, tightly held in a sheath of insulating material 12, conveniently polymerized tetraiiuorethylene, known under the commercial name Teom The words "conductive and insulating are used in their popular sense in the preceding sentence and are ofcourse rielative. Further' details will appear.k The balls l10 may desirably be slightly attened, as shown, at the extremities of a diameter to provide an areav rather than a point of contact between pairs, but it will bev convenientto call them balls. n

The row of balls is connected vinto the electric'lci'reuit at its terminal elements through end plates14, the balls thus being in series connection, electrically considered. The construction as ay whole may have'the exterior .appearance similar to that of the small fuses -used on' atoi mobile circuits, and if suitably designed may be of comparable size and suitable for use in .circuits of that character. I shall hereinafter refer to avgroup of balls or'othr small masses as a cluster, and when' in a single rowias in the modification now being discussed, they might bfe termed a linear cluster as distinguished from afthreedimensional cluster, hereinafter toibe described connectionwith Fig. 7. v A "f As seen in Fig. l the structure'is one which might-` be formed by forcing the balls into a slightly smaller bore 16 in a rod-like body of the insulating material'lft, and in these figures the wall of the bore is shown as somewhat deformed, so that the balls are tightly gripped. filiere should be at least a frictional engagement between ,the insulating material and the balls so that as the dimensions of the insulating material change, motionI is transmitted to the balls, as will be described. In this. instance vthe insulating material is exterior to the balls, that is, they are enclosed in an exterior sheath rather than threaded like beads on a string, and this structure is considered desirable as the insulating material may then itself form the exterior exposed surface bf the device.'` l' t' The balls 10 are conductive, and when they 1are in contact, the cluster serves to pass the normalcurrent for which the device is designed. They should, however, considered as a group have a resistance higher than an equal length of the conducting wires of the circuitso that under an abnormal iiow of current, local heating will occur. Heat so generated will be transmitted to the` insulating material. This material, however, yis so chosen that it has a greater coefhcient of linear expansion'than the balls. It expands and in so doing separates `'two :or more of the balls one from another to break the 'series connection between them. This is shown schematically in Fig. 3, wherein the load on the circuit is shown as shorted by a wire 18. No substantial current now ows' in the external circuit. At the` left of Fig'. l the needle of the meter 20 is shown deected to the right, indicating a iiow of current, whereas in Fig. 3 it has vreturned to the left-hand or zero position. I

It will be understood that the mass and thereforegthe heat absorptive capacity of the insulating body 12 is so chosen as to secure the desired delicacy of responseof the device as a whole. e

The small masses of the conductive cluster in Figs.'2 and 3 are shown and have been described as balls, but the globular form is not necessary. In the modification of Fig. 4 I have shown a series of elongated elements 110 in the form of cylinders of small diameter set end to e`nd.`y By way of simile we may compare them to the lead of of an automatic pencil broken into short pieces. They may conveniently be constructed of carbon. As seen in Fig. 5 a number of these linearclusters of cylindrical masses may be disposed in geometrical and electrical parallelism in'a body or matrix of insulating material 112 between the end plates 14. Passage of a greater quantity o f current isprovided for in this case. The operation is similar t0, that already described and it will be noted that if lthere is a break in one of the linear clusters the heatin'gbfftheothers isgreater until the resistance has built upto such a'degree that the flow of current in the external circuitis negligible in amount. Itfis'anticipated that in the manufacture of themodication of Fig. 4 the linear cluster of masses 110 might be initially afsingle wire-like strip of carbon and after they have been introduced into or covered with the insulating-,mass 112., they could be broken into a multiplicity of segments. Arregular division into equal segments wouldfnot be '2l:1ig'a.'t.ory.`

'In general in av construction such as described in connection with Figs. l-3andin Fig. 4 as so far described,

wher'the current is interrupted the insulating material I2 will promptly cool, shrink,"and return the parts to the positions shown in Figs. l and 4, whereupon if abnormal conditions still exist in the circuit heat will again be generated in the'small masses, the insulating material will again expand, etc. yIf it is desired to keep the device open one may utilize serniconductive, material for the expnsible carrier 112. 'For instance, in the case of tetralorethylene, it might be impregnated with carbon particles(I This is indicated in Fig. 5 by stippling. ln this case when the elements 110 have separated a small amount of current willow through the semi-conductor 112. The resistance will be so great `that the current in the external parts ofthe circuit is negligible, Ybut sutiicient heat will be generatcdtomantain the masses lloseparate'd. In this ,casc'the -current will have to be turned ofi, as by opening the main switch of the circuit, and the structure cooled before it will resume the position of Fig. y4. When Constructed in this manner the insulating material serves as `':lthgh resistance s'hunted around the conductive cluster adis normally short-circuited thereby.

f fln Fig'. 6 I have shown a construction similar to that of Fig. 1 except that in the insulating material 12 a heatingcil'eZZ is inserted, shunted around the cluster of balls T] Theaction willthen be the same as described in conectionrwith Fig. 4. In the drawings, for purposes of deafness. the diagrammatically illustrated resistance coil shown as organized completely at one side of the group of balls rather than coaxially therewith, although such af construction would not probably be utilized in practice. Y

`In Fig. 7 I 'shfow a preferred embodiment of the inventonvfcaplalttlcr of use Yin widely diiering applications. Herein 'a relatively great number of small conductive masses 210 are arranged in what I term a threefdirnensio'naIjcluster. The ,space relationship is like that which wouldbe assumedbyshot poured into a small glass. Shot of.` course would be approximately spherical, dried peas would be approximately, although not perfectly so, andvdried pea beans would not be spherical at all, but the'general structure would be similar in each case and ofv thev typeV sometimes known as a three-dimensional array.4 '."The'rna'sses neednot be identical in size but generally would be all within alimited range of sizes. These Sinallmasses would be in contact with each other and starting-'with one. at one end We could trac various paths through the points of contact in all kinds of meandering's tothe opposite end. Now, if such a cluster of conductive elements. 211)` is: enclosed in avrnatrix 212. of insulating material, the result maybe compared by wayy of metaphor with a conglomerate rockin which a number of pebbles arey cemented together by an external matrix. It may be that not all the. masses 210 will be in Contact with the greatest possible number of adjacent masses, and a few of the masses might be completely' isolated from adjacent ones byY insulating material, ,but there will be a great numherof points of contact and there will be a multi- Varsenaal.

4 tude of conductive paths from one end of the device to the other. We might say that in Fig. l there isV a single linear path for the current, 'that in Fig. 4 there are several paths which we can count arithmetically, while in Fig. 7 there is a multiplicity of paths the number of which we might perhaps estimate statistically. In general the construction resembles operatively that of Fig. 4 without the geometrical regularity, and usually with an increased number of electrically parallel current paths. When the insulating material expands it is not to be anticipated that all these paths will be broken simultaneously, but if one breaks, as already described, the heating eiect increases in the other paths until inally the resistance of the cluster is such as to ciect the desired control action.

It is possible to construct material of the kind shown between the end plates 14 in Fig. 7, as an elongated body of uniform cross section and indefinite length and having a certain ohmic resistance for each unit of length. Thus inthe case of particular applications to provide a desired resistance it will be necessary only to sever a desired length of the material and interpose it between terminals such as the end plates 14 illustrated. Given a great number of substantially identical small masses the number of conductive paths will vary substantially as the cross section ofthe conglomerate, and the cross sectional area of such an elongated body may be chosen to carry a de termined amount of current while the length of a segment of such a body can be related to the source voltage,

in that longer units serve to provide more coincident or near lcoincident series breaks, which reducesthe arcing voltage across each break. From one point of view the products herein described may be considered not as assemblages of mechanically connected elements but as materials of construction in themselves, just as metals or plastics are materials of construction. They may indeed be produced in different forms having different descriptive properties numerically from the electrical standpoint, but each of such forms is a functionally homogeneous material, a portion of which (whether or not severed from a larger supply) may be applied to various uses for which it is suitable.

The constructions hitherto described have functioned electively to break the circuit under abnormal current and thus may be considered as particularly simple and compact forms of self-restoring circuit breakers. It will be clear however that the diierential properties of the small massesy on the one hand, and of the insulation on the other, are involved and the relative expansibilities might be reversed to provide a device which would close the circuit under certain conditions. Thus, if in Fig. 4 the short cylindrical pieces were made of zinc (preferably silver vplated to avoid corrosion at the points of contact) which has a veryY high coeicient of expansion, and the insulator 112 of suitable material having a signicantly lower coecient of expansion (for example, a suitable plastic of the kinds based on an urea-formaldehyde or a melamine-formaldehyde condensation product with a suitable ller, such plastic being impregnated with carbon to provide a semi-conductor), the normal positions of the cylindrical pieces might be spaced to provide a number of airgaps between them and a normal current flowing through the semi-insulator 112 would normally not develop enough heat to expandv them into contact. lf, however, the heat supply were. increased, they would make contact one with"another and form a path of greater conductivity, perhaps diverting the current to ground.l The parts also might be so proportioned as to operate in response to external heating and thus cause closing of the circuit at a given temperature, being in effect a thermostatically controlled switch. I am of course aware that it is old to provide a pair of contacts which are connected by mechanical elements to a thern mally expansible member to be opened or closed in response. to the change in dimensions of such member, but that I do not claim. t

In general the material for the elements will be chosen from the group consisting of carbon and the various metals and alloys, which latter may be cladded or plated on at least their contacting surfaces with silver or the like if they would otherwise be subject to objectionable corrosion at the contacts. A suitable material for the insulating body 12 would be sought for among those commonly utilized for the purpose of insulation, one being chosen having a suitable coeiiicient of expansion in view of the materials used for the small masses and the thermal conditions for which the device is designed. I have found polymerized tetrauorethylene adaptable for many purposes. While my experiments therewith have not been extensive, polymerized trifluorochloroethylene apparently might be useful. If the devices were used in an ambient atmosphere of low temperature as in the case of refrigeration apparatus certain of the materials known by the name of Saran, being copolymers of vinylidene chloride and other monomers might be used as their expansive coeh'icient is large. They will not however stand such high temperatures as the tetrauoroethylene polymer.

I am aware that the invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof, and the present embodiment should therefore be considered in all respects as illustrative and not restrictive, as is in fact clear in several matters from the description itself. Reference is to be had to the appended claims to indicate those principles of the invention exemplified by the particular embodiment described and which it is desired to secure by Letters Patent.

I claim:

1. As a means for controlling the tiow of current in an electric circuit a cluster of small masses most of which are normally in contact one with another and which are of relatively high conductivity to then pass a substantial ow of current, at least certain of said masses being at least in substantial frictional engagement with a mass of material of relatively high resistance which has a relatively great coeicient of expansion under heat and which is free and has suflicient rigidity so that the small masses due to said engagement receive motion therefrom when the mass expands on being heated by transmission thereto of heat developed in the cluster by the application of an abnormal current thereto, whereby the number of contact points among the small masses is reduced to reduce to a negligible value the conductivity of the cluster as a whole.

2. As a means for controlling the flow of current in an electric circuit a three dimensional cluster of small masses, most of which are normally in contact with another at certain areas and which are of relatively high conductivity to then pass a substantial flow of current therethrough, said masses being received within, and at other areas in at least substantial frictional engagement with a matrix of material of relatively high resistance and which has a relatively great coefiicient of expansion under heat so that the small masses due to said engagement will be relatively moved when the matrix expands on being heated by transmission thereto of heat developed in the cluster by the application of an abnormal current thereto, whereby at least certain of formerly contacting masses are separated to reduce to a negligible value the conductivity of the cluster as a whole.

3. A means as set forth in claim l wherein the small masses are substantially globular.

4. A means as set forth in claim 1 wherein the small masses are elongate and presented end to end to one another.

5. A means as set forth in claim 1 wherein said material is a semi-conductor forming a path of high resistance normally short-circuited by the contacting masses and when the short circuit is broken electrically generating sutlicient heat to maintain the system in that condition.

6. A means as set forth in claim 1 wherein a high resistance effective to prevent the supply of substantial current to other parts of the circuit is shunted about the cluster and is normally short-circuited thereby, but is in heat-transmitting relation to the material to maintain it in expanded condition when the short circuit path is open and current is on.

7. A means as set forth in claim 1 wherein the high resistance material provides an external insulating covering for the cluster.

8. As a means for controlling the flow of current in an electric circuit when made a part thereof, a linear cluster of small masses of conductive material which, when touching, provide several pairs of contacts serially arranged at least certain of the masses being at least in substantial frictional engagement with a body of material by which they are suspended, which body has sut`- cient rigidity and is free to expand and contract for relative movement of the small masses on differential thermal expansion of the masses and such body, the small masses and the material of said body having substantially different electric conductivities and markedly different coeicients of thermal expansion.

9. As a means for controlling the ow of current in an electric circuit when made a part thereof, a three-dimensional cluster formed of a multiplicity of small masses of conductive material which, when touching at certain areas, provide a number of current paths, said masses being received within, and at other areas in at least substantial frictional engagement with a matrix of material by which they are suspended for relative movement of the small masses, due to said engagement, on differential thermal expansion of the masses and such matrix, the small masses and the material of said matrix having substantially different electric conductivities and markedly diiferent coeflicients of thermal expansion.

l0. A device for controlling the low of electrical current therethrough, comprising: a carrier body having a bore portion; within said bore portion a plurality of contact bodies of diameters slightly greater than the diameter of the bore portion at areas where it touches a contact body, so that the contact bodies remain at said areas attached to said carrier body, contacting and separating upon changes of dimensions of the carrier and contact bodies; said carrier and contact bodies having appreciably diiferent electrical conductivities and thermal expansions; and terminal means for supplying current to said bodies; whereby contact bodies touch each other or separate upon change of temperature thus controlling the current flow.

1l. Device according to claim 10 wherein said contact bodies are metallic halls.

l2. Device according to claim 1l wherein said balls are slightly attened at adjacent areas.

13. Device according to claim 1l wherein said carrier body is essentially tube-shaped and slightly indented where it touches Said balls.

14. Device according to claim l0 wherein said contact bodies are metallic and said carrier body is a semiconductor.

References Cited inthe le of this patent UNITED STATES PATENTS 1,577,981 Otto Mar. 23, 1926 1,663,810 Morse Mar. 27, 1928 1,728,045 Dubilier Sept. 10, 1929 1,888,762 Greer Nov. 22, 1932 1,913,131 Sission June 6, 1933 2,119,022 Murad May 31, 1938 2,587,916 Squier Mar. 4, 1952 

